Drone Battery Swapping Hub With Robotic Arm and Universal Rail

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Solution Overview

Problem

The limited flight time of autonomous drones due to battery power constraints leads to inefficient and costly manual battery swapping, particularly in fleets, where drones must be grounded and specific battery types are required, limiting their operational range and uptime.

Innovation Solution

A drone hub system equipped with a robotic arm that enables rapid and efficient swapping of batteries using a universal rail system and locking mechanism, allowing for the use of different battery sizes and types, and automated drone handling, reducing manual intervention and downtime.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual battery swapping is used, then specific battery types can be installed, but operational downtime increases and labor costs rise

Engineering Contradiction:

Improvebattery compatibilityVSAvoidoperational downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system enables autonomous battery swapping where the drone independently lands on the charging dock, the robotic arm automatically removes the depleted battery, and a charged battery is installed without human intervention. This self-service mechanism eliminates manual labor and reduces operational downtime significantly.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Batteries are pre-charged and staged at the charging dock before the drone returns. The robotic arm is pre-positioned to immediately exchange batteries upon drone landing. This preliminary preparation ensures that battery replacement occurs rapidly without waiting for charging or manual intervention.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If manual battery replacement is performed, then battery-specific operations can be completed, but labor costs and operational complexity increase

Engineering Contradiction:

Improveflight operations throughputVSAvoidmanual intervention requirement

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The manual mechanical process of battery replacement is substituted with an automated robotic system. The robotic arm with gripper mechanically performs battery removal and installation, while a control system orchestrates the entire process. This replacement of manual mechanical operations with automated mechanical systems increases productivity while reducing operational complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Duration of action of moving object

If drones carry limited battery capacity, then flight time is constrained, but system complexity is reduced

Engineering Contradiction:

Improveflight timeVSAvoidbattery swapping infrastructure

Core Design Contradiction:

Duration of action of moving objectVSDevice complexity

Solution Approach 1:

The battery system is segmented into multiple interchangeable battery units. Instead of requiring a single large battery, the drone uses standardized smaller batteries that can be quickly exchanged. This segmentation allows extended operational duration through battery swaps while keeping individual battery units simple and manageable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The charging dock and robotic arm system serves multiple functions: it charges batteries, stores them, and performs automated exchange operations. This multi-functional infrastructure extends flight time capabilities without proportionally increasing overall system complexity by consolidating functions into a single integrated platform.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20230348122A1Systems and methods for managing loads or manned or unmanned vehicles

Publication Date: 2023.11.02 AIRROW INC

AI summary

A robotic arm configured to load and unload one or more payloads from a drone, the robotic arm comprising: a central body portion; one or more arm sections configured to rotate with respect to the central body portion; one or more end effectors attached to respective end portions of the one or more arm sections; one or more unlocking mechanisms configured to unlock the one or more payloads from the drone; and at least one mechanism configured to remove the one or more payloads from the drone.